Hi Ralph,
Hmmm.... I can get a pdf from it fine here, but I'm using Win 7

The exported pdf from the file in Post 5 is slightly larger than the Post 1 file, but I'm not sure that has anything to do with it.
So, just to make sure we're doing exactly the same thing, here are the exact steps that I'm taking:
- Open the file from Post 5. (I also double-checked to make sure all the Format/Font Styles settings were for a default of 5, in case there was an issue with those settings "sticking".)
- Use File/Export PDF
- Select the Conductor's Score only
- Click OK to begin the export. It goes fairly quickly through the first 80% of the export, then slows considerably, then finishes.
Is there anything that you are doing differently than the above?
ttfn,
Sherry